Fireproof fabric and seat

ABSTRACT

A task is to provide a fire-resistant fabric and a seat each having excellent flame retardancy, fire resistance, strength, comfortability, and formability, and a solution to problem is that a fire-resistant fabric which has a bending resistance of 95 mm or less in the warp direction or in the weft direction, as measured by the method prescribed in JIS L 1096 (2010) A method (45° cantilever method), is obtained using a flame-retardant fiber having an LOI of 26 or more, as measured in accordance with JIS L 1091 (1999) E-2 method.

TECHNICAL FIELD

The present invention relates to a fire-resistant fabric and a seat eachhaving excellent flame retardancy, fire resistance, strength,comfortability, and formability.

BACKGROUND ART

In recent years, as the people's lifestyle is being more advanced, seatcushions for furniture, for bedding articles, especially beds used fornursing home and hospital, and for various facilities of transportationand the like are required to have a heat resistance and flameretardancy. Particularly, with respect to the seat cushion for use inaircraft, it is most important to protect precious lives from flames andthe like, and there are extremely strict flame retardancy standards madeby the Federal Aviation Administration (FAA) regulations.

Conventionally, a cushion of this type generally has fire-resistantfabric called an FBL (Fire Blocking Layer) laminated on a materialhaving elastic properties, such as urethane. With respect to thefire-resistant fabric, for example, PTL 1 has proposed nonwoven fabricusing a flame-resistant fiber.

However, such nonwoven fabric has a problem in that the fabric is sohard that it makes the person who seats on the fabric feeluncomfortable, and it is difficult to seat on the fabric for a longtime.

CITATION LIST Patent Literature

PTL 1: International Patent Application Publication No. 1994/003393pamphlet

SUMMARY OF INVENTION Technical Problem

In view of the above, the present invention has been made, and an objectof the invention is to provide a fire-resistant fabric and a seat eachhaving excellent flame retardancy, fire resistance, strength,comfortability, and formability.

Solution to Problem

The present inventors have conducted extensive and intensive studieswith a view toward achieving the above-mentioned object. As a result, ithas been found that, by appropriately selecting the type of the fiberconstituting the fire-resistant fabric and the cloth structure and thelike, there can be obtained a fire-resistant fabric having excellentflame retardancy, fire resistance, strength, comfortability, andformability, and further extensive and intensive studies have been made,and the present invention has been completed.

Specifically, in the present invention, there is provided “afire-resistant fabric comprising a flame-retardant fiber having an LOIof 26 or more, as measured in accordance with JIS L 1091 (1999) E-2method, wherein the fire-resistant fabric has a bending resistance of 95mm or less in the warp direction or in the weft direction, as measuredby the method prescribed in JIS L 1096 (2010) A method (45° cantilevermethod)”.

In the invention, it is preferred that the fire-resistant fabric has acircular knitted structure. It is preferred that the fire-resistantfabric is formed from double knit. It is preferred that thefire-resistant fabric contains a meta-aramid fiber and a para-aramidfiber and/or an oxidized polyacrylonitrile fiber as the flame-retardantfiber.

Further, the fire-resistant fabric of the invention preferably has aweight per unit of 400 g/m² or less. The fire-resistant fabricpreferably has an air permeability of cm³/cm² sec or more. Thefire-resistant fabric preferably has an elongation of 8% or more, asmeasured in accordance with JIS 1096 (2010) D method (constant loadmethod) Cut strip method, at a distance between two gage marks: 200 mm,and at a constant load: 4.9 N, and has a stretch modulus of 70% or more,as measured in accordance with JIS L 1096 (2010) E method (constant loadmethod) Cut strip method at a constant load: 0.89 N, with repeatingloading: once. The fire-resistant fabric preferably has a burst strengthof 1,000 kPa or more, as measured in accordance with JIS L 1096 (2010) Amethod (Mullen method).

Further, in the invention, a seat having the fire-resistant fabricsandwiched between face fabric and a cushioning material is provided. Inthe seat, it is preferred that the fire-resistant fabric is fixed to theface fabric by sewing. It is preferred that the seat is for use inaircraft, vehicle, rolling stock, vessel, hospital, nursing home,theater, or interior decoration.

Advantageous Effects of Invention

By the present invention, there are obtained a fire-resistant fabric anda seat each having excellent flame retardancy, fire resistance,strength, comfortability, and formability.

DESCRIPTION OF EMBODIMENTS

Hereinbelow, an embodiment of the present invention will be described indetail. The flame-retardant fiber used in the invention is aflame-retardant fiber having an LOI of 26 or more, as measured inaccordance with JIS L 1091 (1999) E-2 method.

With respect to the flame-retardant fiber, for example, wholly aromaticpolyamide fibers, such as a meta-type wholly aromatic polyamide fiber(meta-aramid fiber) and a para-type wholly aromatic polyamide fiber(para-aramid fiber), a polybenzimidazole fiber, a polyimide fiber, apolyamide-imide fiber, a polyether imide fiber, a polyarylate fiber, apolyparaphenylenebenzobisoxazole fiber, a novoloid fiber, aflame-retardant acrylic fiber, a polychlal fiber, a flame-retardantpolyester fiber, a flame-retardant cotton fiber, a flame-retardant rayonfiber, a flame-retardant vinylon fiber, a flame-retardant wool fiber,and the like can be used individually or in combination.

Further, it is preferred that the flame-retardant fiber has a meltingpoint of 300° C. or higher. Examples of such fibers include whollyaromatic polyamide fibers (a meta-type wholly aromatic polyamide fiberand a para-type wholly aromatic polyamide fiber), a polybenzimidazolefiber, a polyimide fiber, a polyamide-imide fiber, and an oxidizedpolyacrylonitrile fiber.

These flame-retardant fibers may contain an additive, such as anantioxidant, an ultraviolet light absorber, a heat stabilizer, a flameretardant, titanium oxide, a coloring agent, or inert fine particles, insuch an amount that the effects aimed at by the invention are notsacrificed.

Particularly, it is preferred that the flame-retardant fiber has an LOIof 26 or more and a melting point of 400° C. or higher. Examples of suchfibers include wholly aromatic polyamide fibers (a meta-type whollyaromatic polyamide fiber and a para-type wholly aromatic polyamidefiber).

The meta-type wholly aromatic polyamide fiber is a fiber formed from apolymer in which 85 mol % or more of the repeating units arem-phenyleneisophthalamide. The meta-type wholly aromatic polyamide maybe a copolymer containing a third component in an amount in the range ofless than 15 mol %.

The meta-type wholly aromatic polyamide can be produced by a knowninterfacial polymerization method, and there is preferably used themeta-type wholly aromatic polyamide having, in terms of the degree ofpolymerization of the polymer, an intrinsic viscosity (I.V.) in therange of from 1.3 to 1.9 dl/g, as measured in the form of anN-methyl-2-pyrrolidone solution of the polymer having a concentration of0.5 g/100 ml.

The meta-type wholly aromatic polyamide may contain analkylbenzenesulfonic acid onium salt. Examples of alkylbenzenesulfonicacid onium salts include compounds, such as tetrabutylphosphoniumhexylbenzenesulfonate, tributylbenzylphosphonium hexylbenzenesulfonate,tetraphenylphosphonium dodecylbenzenesulfonate,tributyltetradecylphosphonium dodecylbenzenesulfonate,tetrabutylphosphonium dodecylbenzenesulfonate, andtributylbenzylammonium dodecylbenzenesulfonate. Of these, especiallypreferred is tetrabutylphosphonium dodecylbenzenesulfonate ortributylbenzylammonium dodecylbenzenesulfonate because they are easilyavailable and have excellent thermal stability as well as highsolubility in N-methyl-2-pyrrolidone.

For obtaining a satisfactory improvement effect for the dyeingproperties, the amount of the alkylbenzenesulfonic acid onium saltcontained is preferably 2.5 mol % or more, preferably in the range offrom 3.0 to 7.0 mol %, based on the mole of thepoly-m-phenyleneisophthalamide.

With respect to the method for mixing poly-m-phenyleneisophthalamidewith an alkylbenzenesulfonic acid onium salt, there is used a method inwhich poly-m-phenyleneisophthalamide is mixed into and dissolved in asolvent and then an alkylbenzenesulfonic acid onium salt is dissolved inthe solvent, or the like. The thus obtained dope is formed into a fiberby a known method.

For the purpose of improving the dyeing properties and the resistance todiscoloration and color fading and the like, with respect to the polymerused in the meta-type wholly aromatic polyamide fiber, which has anaromatic polyamide skeleton comprising repeating structural unitsrepresented by the formula (1) below, an aromatic diamine componentdifferent from the main constituent units of the repeating structure, oran aromatic dicarboxylic acid halide component can be copolymerized as athird component with the aromatic polyamide skeleton so that the amountof the third component becomes 1 to 10 mol %, based on the total mole ofthe repeating structural units of the aromatic polyamide:

—(NH-Ar1-NH—CO-Ar1-CO)—  Formula (1)

wherein Ar1 is a divalent aromatic group having a bonding group at aposition other than the meta position or the parallel axis direction.

As a third component, an aromatic diamine or aromatic dicarboxylic aciddichloride represented by the formula (2), (3), (4), or (5) below can becopolymerized.

Specific examples of aromatic diamines represented by the formula (2) or(3) include p-phenylenediamine, chlorophenylenediamine,methylphenylenediamine, acetylphenylenediamine, aminoanisidine,benzidine, bis(aminophenyl) ether, bis(aminophenyl) sulfone,diaminobenzanilide, and diaminoazobenzene. Specific examples of aromaticdicarboxylic acid dichlorides represented by the formula (4) or (5)include terephthalic acid chloride, 1,4-naphthalenedicarboxylic acidchloride, 2,6-naphthalenedicarboxylic acid chloride,4,4′-biphenyldicarboxylic acid chloride, 5-chloroisophthalic acidchloride, 5-methoxyisophthalic acid chloride, andbis(chlorocarbonylphenyl) ether.

H₂N—Ar2-NH₂  Formula (2)

H₂N-Ar2-Y—Ar2-NH₂  Formula (3)

XOC-Ar3-COX  Formula (4)

XOC-Ar3-Y-Ar3-COX  Formula (5)

Wherein Ar2 represents a divalent aromatic group different from Ar1, Ar3represents a divalent aromatic group different from Ar1, Y represents atleast one atom or functional group selected from the group consisting ofan oxygen atom, a sulfur atom, and an alkylene group, and X represents ahalogen atom.

The crystallinity of the meta-type wholly aromatic polyamide fiber ispreferably 5 to 35% because the absorption for a dye is excellent suchthat an intended color can be easily achieved even when using the dye ina reduced amount or even under poor dyeing conditions. Further, thecrystallinity is more preferably 15 to 25% because localization of a dyein the surface is unlikely to occur and a high resistance todiscoloration and color fading is obtained and further dimensionalstability required for the practical use can be secured.

The residual solvent content of the meta-type wholly aromatic polyamidefiber is preferably 0.1% by weight or less (preferably 0.001 to 0.1% byweight) because excellent flame retardancy of the meta-type whollyaromatic polyamide fiber is not sacrificed.

With respect to the meta-type wholly aromatic polyamide fiber, in viewof obtaining excellent lightfastness, preferred is, for example, thedope-dyed meta-type wholly aromatic polyamide fiber described inInternational Patent Application Publication No. 2013/061901 pamphlet.Examples of pigments used in the fiber include organic pigments, such asazo, phthalocyanine, perinone, perylene, and anthraquinone pigments, andinorganic pigments, such as carbon black, ultramarine blue, red ironoxide, titanium oxide, and iron oxide.

Examples of methods for mixing the meta-type wholly aromatic polyamidewith a pigment include a method in which an amide solvent slurry havinga pigment uniformly dispersed in an amide solvent is prepared, and theamide solvent slurry is added to a solution having the meta-type whollyaromatic polyamide dissolved in an amide solvent, and a method in whicha pigment powder is directly added to a solution having the meta-typewholly aromatic polyamide dissolved in an amide solvent.

The amount of the pigment incorporated is 10.0% by weight or less,preferably 5.0% by weight or less, based on the weight of the meta-typewholly aromatic polyamide. When the pigment is added in an amount ofmore than 10.0% by weight, the obtained fiber is likely to be poor inphysical properties.

With respect to the polymerization method for the meta-type whollyaromatic polyamide polymer, for example, the solution polymerizationmethod or interfacial polymerization method described in JP-B-35-14399,U.S. Pat. No. 3,360,595, JP-B-47-10863, or the like may be used.

As a spinning solution, an amide-solvent solution containing an aromaticcopolyamide polymer obtained by the above-mentioned solutionpolymerization, interfacial polymerization, or the like may be used, ora solution obtained by isolating the polymer from the above-mentionedpolymerization solution and dissolving the polymer in an amide solventmay be used.

Examples of amide solvents used in the polymerization includeN,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-2-pyrrolidone(NMP), and dimethyl sulfoxide.

When the copolymerized aromatic polyamide polymer solution obtained asmentioned above further contains an alkali metal salt or an alkalineearth metal salt, the solution is stabilized and can be advantageouslyused in a higher concentration at low temperatures. The amount of thealkali metal salt or alkaline earth metal salt is preferably 1% byweight or less, more preferably 0.1% by weight or less, based on theweight of the polymer solution. In this case, the polymer solutionpreferably contains a flame retardant.

In the spinning and coagulation step, the above-obtained spinningsolution (meta-type wholly aromatic polyamide polymer solution ordope-dyed meta-type wholly aromatic polyamide polymer solution) isdischarged into a coagulation liquid so as to undergo coagulation.

With respect to the spinning apparatus, there is no particularlimitation, and a known wet spinning apparatus can be used. Further,with respect to the number of spinning holes of a spinning nozzle, thearrangement of the holes, the form of the hole, and the like, there isno particular limitation as long as wet spinning can be stably made,and, for example, a multihole spinning nozzle for rayon yarn having1,000 to 30,000 holes and having a spinning hole diameter of 0.05 to 0.2mm, or the like may be used.

The temperature of the above-obtained spinning solution (meta-typewholly aromatic polyamide polymer solution) being discharged from aspinning nozzle is suitably in the range of from 20 to 90° C.

In a coagulation bath used for obtaining a fiber, an amide solventcontaining substantially no inorganic salt is used. Particularly, anaqueous solution having an NMP concentration of 45 to 60% by weight at abath solution temperature in the range of from 10 to 50° C. ispreferably used. When the amide solvent (preferably NMP) concentrationis less than 45% by weight, a structure having a thick skin isdisadvantageously formed, so that the washing efficiency in the washingstep is lowered, making it difficult to reduce the residual solventcontent of the fiber. On the other hand, when the amide solvent(preferably NMP) concentration is more than 60% by weight, coagulationthroughout the inside of the fiber cannot be achieved, making itdifficult to reduce the residual solvent content of the fiber. The timefor immersing the fiber in the coagulation bath is suitably in the rangeof from 0.1 to 30 seconds.

Drawing is conducted using an amide solvent. Particularly, it ispreferred that, in a plasticized drawing bath containing an aqueoussolution having an NMP concentration of 45 to 60% by weight at a bathsolution temperature in the range of from 10 to 50° C., the fiber issubjected to drawing at a draw ratio of 3 to 4 times. After drawing, theresultant fiber is well washed through an aqueous solution having an NMPconcentration of 20 to 40% by weight at 10 to 30° C. and further througha warm water bath at 50 to 70° C.

The fiber after being washed is subjected to dry heat treatment at atemperature of 270 to 290° C., obtaining a meta-type wholly aromaticpolyamide fiber which satisfies the crystallinity and residual solventcontent in the above-mentioned respective ranges.

By the above-described method, the crystallinity and residual solventcontent in the above-mentioned respective preferred ranges can beachieved.

The meta-type wholly aromatic polyamide fiber may be in the form ofeither a continuous fiber (multifilament) or a short fiber. When mixedwith another fiber, a short fiber having a fiber length of 25 to 200 mmis preferred, and the short fiber having a single fiber fineness of 1 to5 dtex is more preferred.

Further, with respect to the meta-type wholly aromatic polyamide fiber,in view of improving the strength of the cloth, it is preferred that amixed yarn of the meta-type wholly aromatic polyamide fiber and apara-type wholly aromatic polyamide fiber and/or an oxidizedpolyacrylonitrile fiber is contained in the cloth.

The para-type wholly aromatic polyamide fiber used in this case is morepreferably a paraphenyleneterephthalamide fiber or acoparaphenylene-3,4′-oxydiphenyleneterephthalamide fiber.

In the fire-resistant fabric of the invention, the flame-retardant fiberis preferably contained in an amount of 80% by weight or more (morepreferably 100% by weight), based on the cloth weight of thefire-resistant fabric.

With respect to the fiber used in the invention, a multifilament(continuous fiber) or a spun yarn obtained by mix spinning of theabove-mentioned fiber is preferably used. Particularly, from afunctional point of view, a spun yarn is preferred. In this case, thespun yarn is preferably of a yarn count that is generally used forclothing, for example, English cotton yarn count 20 to 60. The spun yarnmay be used in the form of a single yarn or may be used after beingtwisted.

The fire-resistant fabric of the invention is required to have suchstretchability and flexibility that the fabric can follow thedeformation caused during seating and to have air permeability, andtherefore is preferably knitted fabric. The knitted fabric may bewarp-knitted fabric, but is preferably circular knitted fabric(weft-knitted fabric).

When used in the vehicle and aircraft applications, the fire-resistantfabric is required to be lightweight, and is further needed to have heatshield properties, and therefore preferably has a thickness. In view ofthe above, double knit is preferred. The method for producing suchdouble knit may be a known method, and production of the double knit bymeans of a circular knitting machine is preferred.

The structure of the double knit is preferably interlock as a generalstructure, but may be rib, purl, or a modified structure thereof. Forimproving the heat shield properties, a structure having an unevensurface is also preferably used.

With respect to the cloth, it is preferred that, after knitting (orweaving), an oil agent or a wax is removed from the cloth in view ofsurely achieving flame retardancy. Especially preferred is washingprocessing by a general method.

For surely achieving aesthetic properties of a seat using thefire-resistant fabric, it is preferred that the fabric is colored with adeep color, and, for example, black or dark blue pigment dope-dyeing, ordyeing using a carrier, or the like is preferably used. Further, asanother processing for imparting a function, a sweat absorber, a waterrepellent, a thermal storage agent or an antistatic agent, ananti-fungus agent, a deodorant, a mothproofing agent, a mosquitorepellent, a mosquito repellent, a phosphorescent agent, aretroreflective agent, or the like may be applied to the fabric.

It is important that the thus obtained fire-resistant fabric has abending resistance of 95 mm or less (preferably 10 to 80 mm, morepreferably 30 to 60 mm) in the warp direction or in the weft direction,as measured by the method prescribed in JIS L 1096 (2010) A method (45°cantilever method). Particularly, it is preferred that thefire-resistant fabric has a bending resistance of 95 mm or less(preferably 10 to 80 mm, more preferably 30 to 60 mm) in the warpdirection and the weft direction (the wales direction and the coursedirection). When the bending resistance in the warp direction and theweft direction is larger than 95 mm, the fire-resistant fabric is likelyto be so hard that the comfortability or formability becomes poor.

With respect to the fire-resistant fabric of the invention, in view ofthe lightweight properties, it is preferred that the fire-resistantfabric has a weight per unit in the range of 400 g/m² or less(preferably 200 to 400 g/m²). Further, the fire-resistant fabricpreferably has a thickness in the range of 0.5 to 2.0 mm. In view of thecomfortability, the fire-resistant fabric preferably has an airpermeability of 90 cm³/cm² sec or more (more preferably 100 to 300cm³/cm² sec). Further, it is preferred that the fire-resistant fabrichas an elongation of 8% or more, as measured in accordance with JIS 1096(2010) D method (constant load method) Cut strip method, at a distancebetween two gage marks: 200 mm, and at a constant load: 4.9 N, and has astretch modulus of 70% or more, as measured in accordance with JIS L1096 (2010) E method (constant load method) Cut strip method at aconstant load: 0.89 N, with repeating loading: once. In view of surlyobtaining the strength during seating, the fire-resistant fabricpreferably has a burst strength of 1,000 kPa or more (more preferably1,000 to 3,000 kPa), as measured in accordance with JIS L 1096 (2010) Amethod (Mullen method).

In the case of forming a seat by sewing the fabric, for maintainingexcellent appearance even when the fire-resistant fabric is exposedthrough stitches, the fire-resistant fabric preferably has a deep color,i.e., a low lightness, and preferably has an L* of 30 or less (morepreferably 5 to 25), as measured in accordance with JIS Z 8781-4.

Further, the fire-resistant fabric is required to have durability whenexposed to a flame, and therefore, when the fire-resistant fabric issubjected to flame hole forming test in which the fabric is brought intocontact with a burner flame at about 1,100 to 1,200° C. and a period oftime required until the fabric is carbonized and torn is measured, theabove-mentioned time is preferably 100 seconds or more (more preferably200 to 1,000 seconds).

By virtue of having the above-mentioned construction, the fire-resistantfabric of the present invention has excellent flame retardancy, fireresistance, strength, comfortability, and formability.

The fire-resistant fabric is preferably used for a seat. Especiallypreferred is a seat having the fire-resistant fabric sandwiched betweenface fabric and a cushioning material. In the seat, it is preferred thatthe fire-resistant fabric is stacked on the face fabric without using abonding agent. For example, it is preferred that the fire-resistantfabric is fixed to the face fabric by sewing.

For example, it is preferred that the fire-resistant fabric is used asan upholstery backing material, and a cushioning material, such asurethane, is covered with the fire-resistant fabric, and further coveredwith upholstery face fabric. In the seat, it is preferred that the facefabric and the fire-resistant fabric are not bonded but thefire-resistant fabric is partially fixed to the face fabric by sewing orthe like. By virtue of this, formation of wrinkles caused due to adifference between the stretchability of the face fabric and thestretchability of the fire-resistant fabric can be suppressed, and thefire-resistant fabric can exhibit air permeability, so that a seat alsohaving comfortability and the like can be obtained. The seat uses theabove-mentioned fire-resistant fabric, and therefore has excellent flameretardancy, heat shield properties, air permeability, and cushioningproperties.

The seat is advantageously used as a seat for use in aircraft, vehicle,rolling stock, vessel, hospital, nursing home, theater, interiordecoration, or the like.

EXAMPLES

Hereinbelow, the present invention will be described in detail withreference to the following Examples, which should not be construed aslimiting the scope of the invention.

(1) Weight Per Unit

A weight per unit was measured in accordance with JIS L 1096 (2010) Amethod.

(2) Thickness

A thickness was measured in accordance with JIS L 1096 (2010) A method.

(3) Air Permeability

An air permeability was measured in accordance with JIS L 1096 (1990)Air permeability A method (Frajour method).

(4) Burst Strength

A burst strength was measured in accordance with JIS L 1096 (2010) Amethod (Mullen method).

(5) Bending Resistance

A bending resistance was measured in accordance with JIS L 1096 (2010) Amethod (45° cantilever method).

(6) Elongation

An elongation was measured in accordance with JIS 1096 (2010) D method(constant load method) Cut strip method at a distance between two gagemarks: 200 mm, and at a constant load: 4.9 N.

(7) Stretch Modulus

A stretch modulus was measured in accordance with JIS L 1096 (2010) Emethod (constant load method) Cut strip method at a constant load: 0.89N, with repeating loading: once.

(8) Wrinkle Evaluation

An urethane foam was formed into a seating face form, and the doubleknit described in Example 1, 2, or 4 below was cut according to theabove form, and sewn at the corners of the seating face end side, andbonded to the urethane foam in the seating face form using an urethanebonding agent. Further, a leather was cut into forms of the seating faceand the side, and fixed to the double knit by sewing. Further, theseating face of the leather was sewn with the seating face end side.

With respect to the sewing site of the seating face with the seatingface end side, examination was made to check whether or not fine sewingwinkles along the stitches and relatively large wavy winkles formed bywaving of the leather itself were caused, and evaluation was madeaccording to the criteria shown below. The fabric having excellent formfollowing properties is unlikely to cause wrinkles even when covering astructure having a curved sheet form.

◯: Excellent such that neither sewing winkles nor wavy winkles arefound.X: Poor such that both sewing winkles and wavy winkles are found.

(9) Lightness

An L* was measured in accordance with JIS Z 8781-4.

(10) Flame Hole Forming Test

Using a heat source under the conditions shown below, a flame wasbrought into contact with a piece of the double knit described in theExamples below, and simultaneously measurement of a time was started,and a period of time required until the double knit was carbonized and athrough-hole was formed in the knit so that the flame was able to beseen was measured.

Burner: Bunsen burner having an inner diameter of 1.1 to 1.2 mm

Fuel: LP gas

Fuel feed pressure: 0.55 to 0.6 MPa

Height of a flame: 13 to 15 cm

Distance between the burner and the double knit: 7 cm

Example 1

Using the materials shown below, a single yarn of English cotton yarncount 40 was produced by a known method.

(Material)

“Meta-type wholly aromatic polyamide fiber dope-dyed short fiber”:“Conex” (registered trademark), manufactured by Teijin Limited; averagesingle fiber fineness: 1.7 dtex; fiber length: 51 mm (hereinafter,referred to as “meta-aramid fiber”)“Para-type wholly aromatic polyamide short fiber”:“Technora” (registered trademark), manufactured by Teijin Limited;average single fiber fineness: 1.7 dtex; fiber length: 51 mm(hereinafter, referred to as “para-aramid fiber”)

Then, the obtained yarn count 40 single yarn was double-ply twisted at19.8 twists/2.54 cm, and subjected to steam setting at 100° C. for 60minutes.

Using the yarn count 40 double-ply yarn, and using a 20-gauge doubleknit circular knitting machine in which the cylinder diameter is 30inches (1 inch=2.54 cm), and the number of fed yarns for each ofcylinder and dial is 48, knitting of double knit having an interlockstructure was conducted, and the resultant knit was subjected towashing, drying, cutting, and heat setting by a general method. Theobtained double knit had properties and results of the evaluation shownin Table 1.

Example 2

Using the materials shown below, a single yarn of English cotton yarncount 40 was produced by a known method.

(Material)

“Meta-type wholly aromatic polyamide fiber dope-dyed short fiber”:“Conex” (registered trademark), manufactured by Teijin Limited; averagesingle fiber fineness: 1.7 dtex; fiber length: 51 mm (hereinafter,referred to as “meta-aramid fiber”)“Para-type wholly aromatic polyamide short fiber”:“Technora” (registered trademark), manufactured by Teijin Limited;average single fiber fineness: 1.7 dtex; fiber length: 51 mm(hereinafter, referred to as “para-aramid fiber”)“Oxidized polyacrylonitrile fiber”: “Pyromex” (registered trademark),manufactured by Teijin Limited; average single fiber fineness: 2.2 dtex;fiber length: 51 mm

Then, the obtained yarn count 40 single yarn was double-ply twisted at19.8 twists/2.54 cm, and subjected to steam setting at 100° C. for 60minutes.

Using the yarn count 40 double-ply yarn, and using a 20-gauge doubleknit circular knitting machine in which the cylinder diameter is 30inches (1 inch=2.54 cm), and the number of fed yarns for each ofcylinder and dial is 48, knitting of double knit having an interlockstructure was conducted, and the resultant knit was subjected towashing, drying, cutting, and heat setting by a general method. Theobtained double knit had properties and results of the evaluation shownin Table 1.

Example 3

Evaluation for wrinkles was made in substantially the same manner as inthe wrinkle evaluation in Example 1 except that a leather was fixed tothe double knit by bonding the entire surface using an urethane bondingagent, instead of sewing. In the wrinkle evaluation, sewing winkles andwavy winkles were found.

Example 4

Using the material shown below, a single yarn of English cotton yarncount 30 was produced by a known method.

“Unpigmented meta-type wholly aromatic polyamide fiber short fiber”:“Conex” (registered trademark), manufactured by Teijin Limited; averagesingle fiber fineness: 1.7 dtex; fiber length: 51 mm (hereinafter,referred to as “meta-aramid fiber”)

Using the yarn count 30 single yarn, and using a 20-gauge double knitcircular knitting machine in which the cylinder diameter is 30 inches (1inch=2.54 cm), and the number of fed yarns for each of cylinder and dialis 48, knitting of double knit having a tuck mock structure wasconducted, and the resultant knit was subjected to washing, drying,cutting, and heat setting by a general method. The obtained double knithad properties and results of the evaluation shown in Table 1.

TABLE 1 Example 1 Example 2 Example 3 Example 4 Use of yarn CylinderMaterial Meta-aramid fiber 95% 65% 95% 100% Para-aramid fiber 5% 5% 5% —Oxidized acrylic — 30% — — fiber Yarn count 40/2 40/2 40/2 — DialMaterial Meta-aramid fiber 95% 65% 95% 100% Para-aramid fiber 5% 5% 5% —Oxidized acrylic — 30% — — fiber Yarn count 40/2 40/2 40/2 30/1 Gauge 2020 20 20 Course/2.54 cm 37 37 37 37 Wales/2.54 cm 28 28 28 28 StructureInterlock Interlock Interlock Tuck mock Weight per unit g/m² 340 345 340250 Thickness mm 1.3 1.3 1.3 1.0 Air permeability cm³/cm² · sec 110 110110 220 Burst strength kPa 1890 1700 1890 1000 Bending resistance mmWales 51 55 51 30 Course 33 40 33 20 Elongation % Wales 11 9 11 20Course 28.3 25 28.3 50 Stretch modulus % Wales 75.8 72 75.8 80 Course94.1 85 94.1 95 Wrinkle evaluation ◯ ◯ X ◯ L* 19 19 19 86 Flame holeforming sec 262 262 262 4

Comparative Examples 1 and 2

As a meta-type wholly aromatic polyamide fiber, the above-mentioned“Conex” (registered trademark), manufactured by Teijin Limited, wasused, and, as a flame-resistant crimped short fiber, an oxidizedpolyacrylonitrile fiber (“Pyromex” (registered trademark), manufacturedby Teijin Limited; 2.2 dtex; 74 mm) obtained by oxidizing apolyacrylonitrile fiber having a weight residue of 48%, as measured by anonflammability test method, was used. As a thermoplastic elastic fiber,an eccentric sheath-core manner conjugate fiber (single fiber fineness:6.6 dtex) was used, wherein the conjugate fiber was obtained in such away that a block copolymerized polyether polyester elastomer as a sheathportion and polybutylene terephthalate as a core portion were spun by ageneral method so that the core/sheath weight ratio became 50:50, anddrawn at 2.0 times and cut into 64 m, and then subjected to heattreatment with warm water at 95° C. to reduce shrinkage and causecrimps, and dried and then an oil agent was applied to the resultantfiber, wherein the block copolymerized polyether polyester elastomer wasobtained by, while heating, reacting 38% by weight of polybutyleneterephthalate obtained by polymerizing an acid component havingterephthalic acid and isophthalic acid mixed in a 80/20 (mol %) ratioand butylene glycol with 62% by weight of polybutylene glycol (molecularweight: 2,000).

70% by weight of the matrix fiber (the above-mentioned meta-type whollyaromatic polyamide fiber:the above-mentioned oxidized polyacrylonitrilefiber=1:0.2) and 30% by weight of the above-mentioned thermoplasticelastic fiber were subjected to fiber blending by means of a card toobtain a web. The obtained webs were stacked and placed in a mold in aflat plate form so that the thickness became 10 cm, and subjected toheat treatment at 200° C. for 10 minutes. Two types of web specimenshaving different numbers of the webs were prepared. With respect to theobtained webs, the properties and the results of the evaluation areshown in Table 2. Both Comparative Examples 1 and 2 were unsatisfactoryin respect of the burst strength.

TABLE 2 Comparative Comparative Example 1 Example 2 Weight per unit g/m²300 450 Air permeability cm³/cm² · sec 110 90 Burst strength kPa 500 700Bending resistance mm 100 100 Elongation % 30 30 Stretch modulus % 80 80Wrinkle evaluation ○ ○ L* 30 30 Flame hole forming sec 300 or more 300or more

INDUSTRIAL APPLICABILITY

In the present invention, there are provided a fire-resistant fabric anda seat each having excellent flame retardancy, fire resistance,strength, comfortability, and formability, and the invention is ofextremely great industrial significance.

1. A fire-resistant fabric comprising a flame-retardant fiber having anLOI of 26 or more, as measured in accordance with JIS L 1091 (1999) E-2method, wherein the fire-resistant fabric has a bending resistance of 95mm or less in the warp direction or in the weft direction, as measuredby the method prescribed in JIS L 1096 (2010) A method (45° cantilevermethod).
 2. The fire-resistant fabric according to claim 1, which has acircular knitted structure.
 3. The fire-resistant fabric according toclaim 1, which is formed from double knit.
 4. The fire-resistant fabricaccording to claim 1, which contains a meta-aramid fiber and apara-aramid fiber and/or an oxidized polyacrylonitrile fiber as theflame-retardant fiber.
 5. The fire-resistant fabric according to claim1, which has a weight per unit of 400 g/m² or less.
 6. Thefire-resistant fabric according to claim 1, which has an airpermeability of 90 cm³/cm² sec or more.
 7. The fire-resistant fabricaccording to claim 1, which has an elongation of 8% or more, as measuredin accordance with JIS 1096 (2010) D method (constant load method) Cutstrip method, at a distance between two gage marks: 200 mm, and at aconstant load: 4.9 N, and which has a stretch modulus of 70% or more, asmeasured in accordance with JIS L 1096 (2010) E method (constant loadmethod) Cut strip method, at a constant load: 0.89 N, with repeatingloading: once.
 8. The fire-resistant fabric according to claim 1, whichhas a burst strength of 1,000 kPa or more, as measured in accordancewith JIS L 1096 (2010) A method (Mullen method).
 9. A seat having thefire-resistant fabric according to claim 1 sandwiched between facefabric and a cushioning material.
 10. The seat according to claim 9,wherein the fire-resistant fabric is fixed to the face fabric by sewing.11. The seat according to claim 9, which is for use in aircraft,vehicle, rolling stock, vessel, hospital, nursing home, theater, orinterior decoration.
 12. The fire-resistant fabric according to claim 2,which is formed from double knit.